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Heathkit Ig-102 Tuning knob
6/27/2010 1:02:28 PMVinny
Greetings,
I am searching for a Heathkit Ig-102 tuning knob. I finally purchased a signal generator (not the one in the photo), it has to be re-built. The dial pointer has browned and above all the tuning knob is stripped and I can not tighten the 8-32 set screw on to the shaft. If anyone has one and could part with the dial pointer but more importantly the knob itself please contact my e-mail address above. I will pay for it.
Thank you,
Vinny A.


6/27/2010 1:39:43 PMMarv Nuce
Vinny,
If the set screw is the only problem, drill the hole for a #10-32 screw and re-tap (new threads)

marv

:Greetings,
:I am searching for a Heathkit Ig-102 tuning knob. I finally purchased a signal generator (not the one in the photo), it has to be re-built. The dial pointer has browned and above all the tuning knob is stripped and I can not tighten the 8-32 set screw on to the shaft. If anyone has one and could part with the dial pointer but more importantly the knob itself please contact my e-mail address above. I will pay for it.
:Thank you,
:Vinny A.
:
:
:
:
:

6/27/2010 4:45:35 PMVinny
Marv, I have not done that before. What size drill bit is needed for a 10-32? Do you need a tool that re-threads or will the screw make its own threads or crack the knob from inside?
Thanks,
Vinny A.

:Vinny,
:If the set screw is the only problem, drill the hole for a #10-32 screw and re-tap (new threads)
:
:marv
:
::Greetings,
::I am searching for a Heathkit Ig-102 tuning knob. I finally purchased a signal generator (not the one in the photo), it has to be re-built. The dial pointer has browned and above all the tuning knob is stripped and I can not tighten the 8-32 set screw on to the shaft. If anyone has one and could part with the dial pointer but more importantly the knob itself please contact my e-mail address above. I will pay for it.
::Thank you,
::Vinny A.
::
::
::
::
::
:

6/27/2010 6:09:40 PMDoug Criner
Google 10-32 thread dimensions. Or better yet - and simpler - take the setscrew and match its minor diameter to one of your bits. Use a 10-32 tap to make the threads. I'm afraid trying to use the setscrew to make the threads will gum up the hole.
6/27/2010 6:11:11 PMDoug Criner
Correction: I meant 8-32.
6/28/2010 12:49:07 AMMarv Nuce
Vinny,
For a 10-32 screw use a #21 (0.159") drill bit, and yes, you'll need a 10-32 tap from a hardware store. You might find a 10-32 self tapping screw, but won't be a set screw. Another option is to fill the hole with JB Weld epoxy, and re-tap for the 8-32. You could actually smear a little epoxy around, inside the threads, wait a few minutes, thread in a normal 8-32 screw, then back it out. Let the epoxy dry, then insert the set screw. Again a self tapping 8-32 screw from the hardware will cut new threads in the epoxy, then use the regular 8-32 set screw.

marv

:Marv, I have not done that before. What size drill bit is needed for a 10-32? Do you need a tool that re-threads or will the screw make its own threads or crack the knob from inside?
:Thanks,
:Vinny A.
:
:
:
::Vinny,
::If the set screw is the only problem, drill the hole for a #10-32 screw and re-tap (new threads)
::
::marv
::
:::Greetings,
:::I am searching for a Heathkit Ig-102 tuning knob. I finally purchased a signal generator (not the one in the photo), it has to be re-built. The dial pointer has browned and above all the tuning knob is stripped and I can not tighten the 8-32 set screw on to the shaft. If anyone has one and could part with the dial pointer but more importantly the knob itself please contact my e-mail address above. I will pay for it.
:::Thank you,
:::Vinny A.
:::
:::
:::
:::
:::
::
:

6/28/2010 7:19:00 AMEdd








Sir Vinny . . . . . .



Ye olde Knob:


And with the unit old enough to be hopefully not getting the later influx of Japonie knobs being supplied and their metric screws, and the threading hopefully being not the first 6-32 . . not beefy enough, along with their tips provided surfactal area . . . but very probably a 8-32 . . .but a 10-32 would be getting on towards the probable max size.


(Forbid that its not a 10-24)


Now the next fallacy, in the probability of the upping from a found 8-32 up to a 10-32, is that finite short distance between the hole and the opposite end of that 1/4 in hole in the brass? insets collar.
The conventional tap which you are going to find at the Home Despot or Lowes(T) is going to have you then finding that the gradual chamfering of the initial starting part of the tap will have you bottoming out against the opposite wall of the collar.
That being EVEN before you have established a good chasing out of the smaller threading size and re established into a perfected reforming to the NEW thread size . . . THROUGHOUT its length.


The alternative ?.. The journeyman machinist would merely reach in his tool drawer and pull out that which is known as a chaser tap, which is one that has no LONG GRADUAL TAPERING of the threading onset, but merely a very slight chamfer on the first 2 or so threads . It would then establish a conforming threading the whole lenghth of the collar and still not be bottoming out against the opposite collar wall.
In my case I have made several of these from the remnants of past times broken off taps, by the use of a Dremel tool and a cut off wheel.


What wud I does ?


I would figure on your trip to the hardware store and getting an 1/8 hi speeeeed drill bit and both a 6-32 and an 8-32 tap.( That 1/8 size is a bit larger than the specified numerical size for that taps use but it is cheeeper and more commonly found AND the final chasing out to upsizing to the 8-32 size will have then left a nice conformal fit.


Then the old set screw is removed and the drill held in the best alignment to pass the drill bit thru the old "wallered" out hole and drill a hole thru the inset 1/4 in collars OPPOSITE wall and on out the opposite side of the knobs plastic /or /bakelite surround.


Then you tap thru the old hole and initially start and finally finish up by passing out the NEWLY drilled hole.
Then the 8-32 top will easily start in the existant 6-32 threading and establish a VERY conformal threading to the final sizing, with no end play limitation due to the old hole letting the tap end travel into that old open area.


Then install a set screw.


Hint:


Lubricant on the tap a must and once the initial 2 turns are established for a start off "bite", then the sequential 1/2 a turn of tapping and then back up 3/4 turn,for chasing then forward to get a fresh 1/2 turn then 3/4 turn back . . .etc,etc. over and over.


Hard to remember the last time I even had a tap sieze or had one break on me since doing that back up sequence, particularly with steel or a stainless steel block being the real challenge, your non ferrous metals . . . are a snap.

A Shiny New Pointer:


NOW the way I used to make my own custom pointers for my custom communications / ham receivers.
Very much akin to that Heath knob of yours, cept I opted for a narrow long rectangle with the corners rounded off. Yours . . . instead . . . is being a gradually tapered to the tip pointer.


I'm expecting the rear of the knob to be having 3 small screws affixing the pointer to the knob back. Get the pointer free and figure the dimensions of the needed replacement piece of plastic.


Then the hunt is on for the replacement plastic, now I would think that the MINIMUM size in thickness would be about two thickness of playing cards, as you know how stable that even 1 thickness is in holding its shape. On the other end of the thickness spectrum might be up to an 1/8 of an inch. Then you scour the house / garage/shop to then see what you have that might fulfill the supplying of that piece of clear plastic.


Or walk the "Dollar" - Thrift store aisles to see what found obscure item just might additionally fulfill YOUR needs in magnificently providing a piece of plastic of that size.


Then . . . going full list price mode . . .I know that there are plastic picture frame "glass" inserts. . . . but possibly overpriced for its plastics scrap value.


Also . . . Dritz pattern maker template for the home seamstress . . highly overpriced at $4.95 for its plastic.
Check Homeless Despot or Lowes(T) for a small Plexiglass cut off scrap . . for free . . in their cut off bin . . . BUT, avoid softer Lexar as its quite a bear to refinish a cut edge on . . .with the most successfull technique being the multiple drags of an almost vertical box cutters sharp blade in a scraping action of taking away curls of plastic. PLUS it also has an offensive subtle blue coloration to it.


If using Plexiglass, a sheet of wetted # 400 wet and dry sandpaper on a flat surface and then working the cut edges of the created plastic pointer across it will finally yield a matte finish.


Then, if a perfectly clear finish is needed from that matte surface, the soaking of a sheet of paper with Brasso and working on the same flat surface, will eventually give a pristine, glass clear finish on the Plexiglass edges.
The centered HAIRLINE mark is made by initially marking in its extreme end limits with a micro tip Blue Sharpie on the BACK side of your plastic pointer. Then double check to see that it is centered. Then at the NARROW dimension of the pointer end, you might need a scrap of that plastic to the side to fully support a wooden/stainless steel(cork backed) ruler that you will line up beside the alignment marks.


The cut/scribe will be done with an Exacto knife with a fresh #11 blade mounted in it, but you will be using it BACKWARDS as a vee scratching tool, with it held about 30 degrees down from the vertical.


Make a trial movement the whole length between the two indexing marks, with out touching the plastic and then touch lightly to make an initial slight scratching the length of then a few more runs to develop just a bit of a progressively deeper vee groove in the plastic. . . but it doesn't need to be excessively deep !


Then the groove gets filled in with your black coloring agent, thru the times I have used a black china marker(aka price marker, grease pencil ?), black crayola, India ink, Ki Wi shoe polish (solid . .not liquid), enamel paint in a can. Needless to say any Sharpie perm types of markers are out, since they tend to leave a subtle stain on any overcreep at the side of the line which mineral spirits / lighter fluid /naptha/ "409" won't quite take out. While, more agressive clean up solvents are going to react ADVERSELY with your plastic.


(Inclusive of MEK, toluene, xylene, acetone, methyl chloride, lacquer thinner and bannana oil, etc / what ? else.)

Thassit . . . .did you get the point(er) ?



73's de Edd








:Vinny,
:For a 10-32 screw use a #21 (0.159") drill bit, and yes, you'll need a 10-32 tap from a hardware store. You might find a 10-32 self tapping screw, but won't be a set screw. Another option is to fill the hole with JB Weld epoxy, and re-tap for the 8-32. You could actually smear a little epoxy around, inside the threads, wait a few minutes, thread in a normal 8-32 screw, then back it out. Let the epoxy dry, then insert the set screw. Again a self tapping 8-32 screw from the hardware will cut new threads in the epoxy, then use the regular 8-32 set screw.
:
:marv

FONT SIZE=4 FACE="Comic Sans MS"COLOR=00ff00>
:
::Marv, I have not done that before. What size drill bit is needed for a 10-32? Do you need a tool that re-threads or will the screw make its own threads or crack the knob from inside?
::Thanks,
::Vinny A.
::
FONT SIZE=4 FACE="Comic Sans MS"COLOR=00ff00>::
::
:::Vinny,
:::If the set screw is the only problem, drill the hole for a #10-32 screw and re-tap (new threads)
:::
:::marv

FONT SIZE=4 FACE="Comic Sans MS"COLOR=ff00ff>
:::
::::Greetings,
::::I am searching for a Heathkit Ig-102 tuning knob. I finally purchased a signal generator (not the one in the photo), it has to be re-built. The dial pointer has browned and above all the tuning knob is stripped and I can not tighten the 8-32 set screw on to the shaft. If anyone has one and could part with the dial pointer but more importantly the knob itself please contact my e-mail address above. I will pay for it.
::::Thank you,
::::Vinny A.
::::
::::
::::
::::
::::
:::
::
:

7/23/2010 12:12:51 PMVinny
Dr. Edd, sorry it took me so long to respond, and thank you for your response.

The knob was drilled and re-tapped for a 10/32 and worked great, it does continue to turn when the dial and tuner reach the end of the road. It does leave a scratch on the tuner shaft if you keep on turning it. However, I broke the plastic dial so the job is on hold and I am unable to see the turns ratio of the knob to dial.(not terrible because the generator was free). I bought another one and I am waiting for it to come. I will respond when it does come.
Thank you,
Vinny A.

6/28/2010 10:06:49 PMJohnny
:And if all else fails I'm putting my Heath IG-102S on Epay July 8th. It has been rebuilt and has been a worthy piece of equipment but I have since moved on to an Eico I like. Mine has RF Direct jacks under the big knob that you need and I converted to BNC jacks on the RF and Audio output. Mine does need calibration and is flakey above 100 mHz so FM alignment would be difficult. I figure mine would make a good parts set if someone didn't want to bother with cal. and the 100mHz issues.
Johnny
:
:Greetings,
:I am searching for a Heathkit Ig-102 tuning knob. I finally purchased a signal generator (not the one in the photo), it has to be re-built. The dial pointer has browned and above all the tuning knob is stripped and I can not tighten the 8-32 set screw on to the shaft. If anyone has one and could part with the dial pointer but more importantly the knob itself please contact my e-mail address above. I will pay for it.
:Thank you,
:Vinny A.
:
:
:
:
:
7/1/2010 2:13:25 PMVinny
Marv, Doug, Edd, and Johnny,
Thank you for your time and advice, I will have to use one of these methods but a knob would speeeeeed up the process.
Dr. Edd, that explanation has a lot of medical terminology. I have to print it and take it to work and read it with a specialist; the screw is an 8-32. I have a limited amount of tools, but I am trying to accumulate them. I have to get to a hardware store so this may take a while.
Thank you,
Vinny A.

7/10/2010 12:12:41 PMVinny
Greetings,
I took the knob to a hardware store and the worker drilled and re-tapped the knob hole for 10/32 and just put a machine screw in the place for a set screw which de did not have. It sat well on the tuning shaft and turned the dial. However, when the dial and tuning condenser stopped turning in each direction, the knob and screw kept turning as if it was sliding on the tuning shaft.
I am wondering if there is a part missing in the knob which puts pressure on the shaft and keeps the screw from continuously turning. Constantly the screw will have to be tightened as it wears down the metal of the tuning shaft.
I also tried a similar knob with a 8/.32 setscrew in it that did the same thing.
Does any one have this issue with their generator or any suggestions.
Vinny A.

7/10/2010 12:38:09 PMWarren
Might try drilling a countersink in the shaft. Some tuner shafts on radios have that so there is no slippage.
7/10/2010 7:05:52 PMVinny
Warren, great idea! I will try that, I wonder how difficult it will be to try and drill something small, metal, and round.
Thank you,
Vinny A.
7/10/2010 8:09:02 PMMarv Nuce
Vinny,
Another approach might be to file/grind a flat spot on the shaft. Most pot/tuning shafts using set screws have a flat to avoid just the symptom you're describing, assuming other components of the mechanism isn't binding.

marv

:Warren, great idea! I will try that, I wonder how difficult it will be to try and drill something small, metal, and round.
:Thank you,
:Vinny A.
:

7/12/2010 12:30:59 AMVinny
Marv, thank you.
I was setting up to either drill or grind the shaft.
I detoured and tried to clean the dial pointer which was brown. Then came a snap, and the dial pointer broke off into a couple of pieces. Silence for 10 minutes.
Thanks anyway,
Vinny A.
7/12/2010 10:56:24 AMWarren
Time to get inventive again. Glue the old parts together. use that for template. Find some clear plastic. It don't have to be the same gage. Just stiff enough to be workable. Scribe a center line down the middle of the pointer. There is no stress on the pointer itself. It just needs to be an indicator.
7/12/2010 11:54:26 AMMarv Nuce
Vinny,
Might find just the right piece of plastic for your pointer in the school supply section of many drugstores. Maybe even a uniquely colored protractor/ruler with a line already scribed. Craft shops will have an even bigger offering. An old CD cut to shape may offer unique color spectra and irridescence, lacking only the pointer line.

marv

:Marv, thank you.
:I was setting up to either drill or grind the shaft.
:I detoured and tried to clean the dial pointer which was brown. Then came a snap, and the dial pointer broke off into a couple of pieces. Silence for 10 minutes.
:Thanks anyway,
:Vinny A.
:

7/13/2010 9:27:42 PMVinny
Warren and Marv, thank you so much for your time, advice, and expertise.
I am going to have to wait some time before I try this.
Thank you again,
Vinny A.
7/12/2010 6:48:51 PMGary W. Prutchick
Hi Vinny,

This is completely normal for this signal generator.


Gary


:Greetings,
:I took the knob to a hardware store and the worker drilled and re-tapped the knob hole for 10/32 and just put a machine screw in the place for a set screw which de did not have. It sat well on the tuning shaft and turned the dial. However, when the dial and tuning condenser stopped turning in each direction, the knob and screw kept turning as if it was sliding on the tuning shaft.
:I am wondering if there is a part missing in the knob which puts pressure on the shaft and keeps the screw from continuously turning. Constantly the screw will have to be tightened as it wears down the metal of the tuning shaft.
:I also tried a similar knob with a 8/.32 setscrew in it that did the same thing.
:Does any one have this issue with their generator or any suggestions.
:Vinny A.
:
:

7/13/2010 9:25:16 PMVinny
Gary, thank you.
Vinny A.


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